I. Achieving Efficient PE Film Recycling through Advanced Compacting and Pelletizing Technology
With the growing demand for sustainable plastic recycling, the recycling of PE (polyethylene) film has become a crucial pathway for reducing plastic waste and improving resource utilization. However, due to characteristics such as low bulk density, high flexibility, and a tendency to tangle, traditional recycling methods often face challenges including unstable feeding, inadequate plasticization, moisture issues, and poor pellet quality.
ACERETECH offers an efficient PE film recycling solution based on the ACS single-screw compacting pelletizer. This solution integrates material compacting, gentle melting, vacuum degassing, continuous filtration, and pelletizing processes into a single, comprehensive system.
This recycling system is suitable for pelletizing clean and lightly contaminated PE film, capable of producing high-quality recycled plastic pellets with stable output and excellent processing performance.
II. Recycled Material: PE Film
PE (polyethylene) film is one of the most widely used plastic materials globally, commonly found in the following applications:
Packaging film
Agricultural film
Shopping bags
Industrial packaging waste
Stretch wrap film
Blown film production waste
Due to its lightweight and flexible nature, PE film waste is more difficult to process than rigid plastics.
Key challenges in PE film recycling include:
● Low bulk density, leading to unstable feeding
● Tendency for tangling and bridging during the feeding process
● High moisture and impurity content
● Material degradation caused by excessive heat during processing
Therefore, employing an effective compacting and extrusion-pelletizing process is essential for achieving stable recycling results.
III. PE Film Recycling Process Flow
The ACS PE film recycling system primarily comprises the following stages:
Belt Feeding → Compacting → Single-Screw Extrusion → Vacuum Degassing → Continuous Filtration → Water-Cooled Strand Pelletizing → Pellet Collection
1. Belt Feeding System with Metal Detection
PE film scrap is continuously conveyed into the compaction chamber via a belt conveyor equipped with a metal detector.
The metal detection system identifies and rejects metal impurities before the material enters the extruder, thereby protecting critical equipment components and enhancing production reliability.
Advantages:
Stable automatic feeding
Reduced risk of equipment damage
Improved operational safety
2. Efficient Material Compaction
The 300-liter capacity compaction chamber plays a pivotal role in processing lightweight PE film. Before entering the extrusion system, loose film material undergoes compression, densification, and pre-heating via high-speed rotating blades.
This process helps to:
Increase material bulk density
Improve feeding stability
Prevent material bridging (clogging)
Enhance overall production efficiency
3. Gentle Plasticization via Single-Screw Extrusion System
The ACS system features a single-screw extruder with an 80mm screw diameter, offering high output and low energy consumption despite its compact screw size.
The optimized screw design provides excellent melting and mixing capabilities while ensuring gentle plasticization of the PE material.
Compared to high-shear processing, gentle plasticization helps to:
Minimize material degradation
Maintain the quality of recycled pellets
Improve production stability
4. Dual-Stage Vacuum Degassing System for Superior Pellet Quality
During the PE film recycling process, moisture and volatile substances can affect the quality of the final pellets. The ACS pelletizing system utilizes a dual-stage vacuum degassing system to effectively remove:
Moisture
Air bubbles
Low-molecular-weight substances
Volatile impurities
Its advantages include:
Reduced pellet defects
Improved visual quality
More stable recycled material performance
5. Continuous Piston-Type Screen Changer
The system is equipped with a P650 continuous piston-type screen changer.
Screen changes can be performed during operation without stopping the machine, ensuring continuous production.
Advantages:
Higher production efficiency
Reduced downtime
Stable melt filtration performance
6. Water-Cooled Strand Pelletizing System
Extruded molten plastic strands enter a water-cooling system for rapid cooling.
The cooled strands are then cut into uniform recycled pellets.
The resulting pellets are:
Uniform in size
Consistent in quality
Suitable for reuse in plastic manufacturing applications
After pelletizing, the finished pellets undergo air cooling and are automatically conveyed to storage silos via a pneumatic conveying system.
Related Articles
PE Film In-Plant Recycling Solutions
PE Film Washing Solutions
PE Film Shredding Solutions
IV. Advantages of the ACS PE Film Recycling Solution
1. Stable Processing of Lightweight Film Materials
The pre-compaction system improves feeding performance, resolving common feeding challenges associated with low-density PE films.
2. High-Quality Recycled Pellets
The combination of optimized screw design, vacuum degassing, and continuous filtration ensures superior pellet quality.
3. Continuous, Efficient Production
The automatic filtration system reduces downtime and boosts production efficiency.
4. Wide Range of Applications
The system is suitable for various PE film recycling scenarios, including industrial film scrap and post-consumer plastic film.
5. Intelligent Operation
An intelligent PLC control system enables convenient equipment operation, real-time monitoring of operating parameters, and stable control of the production process.
Key electrical components feature variable frequency drives (VFDs), ensuring flexible operation and stable performance while effectively reducing labor costs.
Conclusion
PE film recycling requires reliable technology to overcome challenges such as low material density, unstable feeding, and moisture contamination.
The ACERETECH ACS single-screw compactor-pelletizer integrates compaction, extrusion, vacuum degassing, filtration, and pelletizing technologies into one system, providing an efficient and practical recycling solution. The ACS system delivers a stable output (100–200 kg/h), enabling plastic recyclers to transform PE film waste into high-value recycled plastic pellets while enhancing production efficiency and sustainability.
FAQ
Q1. What types of PE film can the ACS pelletizer recycle?
A: The ACS single-screw compacting pelletizer handles a wide range of PE film materials, including LDPE film, LLDPE stretch wrap, industrial packaging film, agricultural film, and PE production scrap. System configurations can be tailored based on material contamination levels and moisture content.
Q2. Why is a compaction system necessary for PE film recycling?
A: PE film has a low bulk density and is prone to compression or tangling during the feeding process. A pre-compaction silo increases material density, stabilizes feeding, and prevents issues such as bridging (material clogging) and uneven extrusion.
Q3. What are the advantages of the dual-vacuum degassing system in plastic pelletizing?
A: The dual-vacuum degassing system effectively removes moisture, air, and volatile substances from the molten plastic. This helps minimize bubbles, improves pellet appearance, and ensures consistent pellet quality.
Q4. Can the ACS pelletizer operate continuously without stopping to change screens?
A: Yes. The ACS system can be equipped with a P650 piston-type continuous screen changer, allowing for screen replacement during production without downtime, thereby significantly boosting productivity.
Q5. What is the production capacity of the ACS PE film recycling machine?
A: The ACS single-screw compacting pelletizer featured here has a production capacity of 100–200 kg/h. ACERETECH offers various models and configurations tailored to specific raw materials, output requirements, and recycling goals.